US4300968A - Method for bonding fibrous web materials - Google Patents
Method for bonding fibrous web materials Download PDFInfo
- Publication number
- US4300968A US4300968A US06/104,770 US10477079A US4300968A US 4300968 A US4300968 A US 4300968A US 10477079 A US10477079 A US 10477079A US 4300968 A US4300968 A US 4300968A
- Authority
- US
- United States
- Prior art keywords
- prepolymer
- fibrous web
- web
- rollers
- binder
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 238000000034 method Methods 0.000 title claims abstract description 47
- 239000000463 material Substances 0.000 title description 22
- 239000011230 binding agent Substances 0.000 claims abstract description 62
- 239000000835 fiber Substances 0.000 claims description 30
- 239000000203 mixture Substances 0.000 claims description 20
- 239000000178 monomer Substances 0.000 claims description 16
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 9
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 claims description 6
- 229910052753 mercury Inorganic materials 0.000 claims description 6
- 238000002844 melting Methods 0.000 claims description 5
- 229920002635 polyurethane Polymers 0.000 claims description 5
- 239000004814 polyurethane Substances 0.000 claims description 5
- DAKWPKUUDNSNPN-UHFFFAOYSA-N Trimethylolpropane triacrylate Chemical compound C=CC(=O)OCC(CC)(COC(=O)C=C)COC(=O)C=C DAKWPKUUDNSNPN-UHFFFAOYSA-N 0.000 claims description 4
- 230000008018 melting Effects 0.000 claims description 4
- 229920000728 polyester Polymers 0.000 claims description 4
- 230000005855 radiation Effects 0.000 claims description 4
- 238000004132 cross linking Methods 0.000 claims description 3
- 238000009499 grossing Methods 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- MYWOJODOMFBVCB-UHFFFAOYSA-N 1,2,6-trimethylphenanthrene Chemical compound CC1=CC=C2C3=CC(C)=CC=C3C=CC2=C1C MYWOJODOMFBVCB-UHFFFAOYSA-N 0.000 claims description 2
- 229920001730 Moisture cure polyurethane Polymers 0.000 claims description 2
- HVVWZTWDBSEWIH-UHFFFAOYSA-N [2-(hydroxymethyl)-3-prop-2-enoyloxy-2-(prop-2-enoyloxymethyl)propyl] prop-2-enoate Chemical compound C=CC(=O)OCC(CO)(COC(=O)C=C)COC(=O)C=C HVVWZTWDBSEWIH-UHFFFAOYSA-N 0.000 claims description 2
- 229920002239 polyacrylonitrile Polymers 0.000 claims description 2
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 claims 2
- 229920001778 nylon Polymers 0.000 claims 1
- 229920002994 synthetic fiber Polymers 0.000 abstract description 3
- 239000012209 synthetic fiber Substances 0.000 abstract description 2
- 229920005989 resin Polymers 0.000 description 8
- 239000011347 resin Substances 0.000 description 8
- 239000003999 initiator Substances 0.000 description 7
- 239000002904 solvent Substances 0.000 description 6
- 238000007792 addition Methods 0.000 description 5
- 238000006116 polymerization reaction Methods 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 125000005396 acrylic acid ester group Chemical group 0.000 description 4
- 238000005108 dry cleaning Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000003287 optical effect Effects 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 150000002148 esters Chemical class 0.000 description 3
- 238000009281 ultraviolet germicidal irradiation Methods 0.000 description 3
- 238000005303 weighing Methods 0.000 description 3
- KWVGIHKZDCUPEU-UHFFFAOYSA-N 2,2-dimethoxy-2-phenylacetophenone Chemical compound C=1C=CC=CC=1C(OC)(OC)C(=O)C1=CC=CC=C1 KWVGIHKZDCUPEU-UHFFFAOYSA-N 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- RWCCWEUUXYIKHB-UHFFFAOYSA-N benzophenone Chemical compound C=1C=CC=CC=1C(=O)C1=CC=CC=C1 RWCCWEUUXYIKHB-UHFFFAOYSA-N 0.000 description 2
- 239000012965 benzophenone Substances 0.000 description 2
- 238000003490 calendering Methods 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- DOIRQSBPFJWKBE-UHFFFAOYSA-N dibutyl phthalate Chemical compound CCCCOC(=O)C1=CC=CC=C1C(=O)OCCCC DOIRQSBPFJWKBE-UHFFFAOYSA-N 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000012299 nitrogen atmosphere Substances 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000005406 washing Methods 0.000 description 2
- VOBUAPTXJKMNCT-UHFFFAOYSA-N 1-prop-2-enoyloxyhexyl prop-2-enoate Chemical compound CCCCCC(OC(=O)C=C)OC(=O)C=C VOBUAPTXJKMNCT-UHFFFAOYSA-N 0.000 description 1
- PIZHFBODNLEQBL-UHFFFAOYSA-N 2,2-diethoxy-1-phenylethanone Chemical compound CCOC(OCC)C(=O)C1=CC=CC=C1 PIZHFBODNLEQBL-UHFFFAOYSA-N 0.000 description 1
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- DZZAHLOABNWIFA-UHFFFAOYSA-N 2-butoxy-1,2-diphenylethanone Chemical compound C=1C=CC=CC=1C(OCCCC)C(=O)C1=CC=CC=C1 DZZAHLOABNWIFA-UHFFFAOYSA-N 0.000 description 1
- KMNCBSZOIQAUFX-UHFFFAOYSA-N 2-ethoxy-1,2-diphenylethanone Chemical compound C=1C=CC=CC=1C(OCC)C(=O)C1=CC=CC=C1 KMNCBSZOIQAUFX-UHFFFAOYSA-N 0.000 description 1
- OMIGHNLMNHATMP-UHFFFAOYSA-N 2-hydroxyethyl prop-2-enoate Chemical compound OCCOC(=O)C=C OMIGHNLMNHATMP-UHFFFAOYSA-N 0.000 description 1
- CDFSOKHNACTNPU-GHUQRRHWSA-N 3-[(1r,3s,5s,8r,9s,10s,11r,13r,17r)-1,5,11,14-tetrahydroxy-10,13-dimethyl-3-[(2r,3r,4r,5s,6s)-3,4,5-trihydroxy-6-methyloxan-2-yl]oxy-2,3,4,6,7,8,9,11,12,15,16,17-dodecahydro-1h-cyclopenta[a]phenanthren-17-yl]-2h-furan-5-one Chemical compound O[C@@H]1[C@H](O)[C@H](O)[C@H](C)O[C@H]1O[C@@H]1C[C@@]2(O)CC[C@H]3C4(O)CC[C@H](C=5COC(=O)C=5)[C@@]4(C)C[C@@H](O)[C@@H]3[C@@]2(C)[C@H](O)C1 CDFSOKHNACTNPU-GHUQRRHWSA-N 0.000 description 1
- QZPSOSOOLFHYRR-UHFFFAOYSA-N 3-hydroxypropyl prop-2-enoate Chemical compound OCCCOC(=O)C=C QZPSOSOOLFHYRR-UHFFFAOYSA-N 0.000 description 1
- JHWGFJBTMHEZME-UHFFFAOYSA-N 4-prop-2-enoyloxybutyl prop-2-enoate Chemical compound C=CC(=O)OCCCCOC(=O)C=C JHWGFJBTMHEZME-UHFFFAOYSA-N 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- CYTYCFOTNPOANT-UHFFFAOYSA-N Perchloroethylene Chemical group ClC(Cl)=C(Cl)Cl CYTYCFOTNPOANT-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 206010040880 Skin irritation Diseases 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- GSEJCLTVZPLZKY-UHFFFAOYSA-N Triethanolamine Chemical compound OCCN(CCO)CCO GSEJCLTVZPLZKY-UHFFFAOYSA-N 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 238000001994 activation Methods 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000007596 consolidation process Methods 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 229960002380 dibutyl phthalate Drugs 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 230000002427 irreversible effect Effects 0.000 description 1
- 238000011031 large-scale manufacturing process Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- CRVGTESFCCXCTH-UHFFFAOYSA-N methyl diethanolamine Chemical compound OCCN(C)CCO CRVGTESFCCXCTH-UHFFFAOYSA-N 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 235000019645 odor Nutrition 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000000979 retarding effect Effects 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 230000036556 skin irritation Effects 0.000 description 1
- 231100000475 skin irritation Toxicity 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 238000005496 tempering Methods 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 238000007725 thermal activation Methods 0.000 description 1
- 230000001988 toxicity Effects 0.000 description 1
- 231100000419 toxicity Toxicity 0.000 description 1
- 229960004418 trolamine Drugs 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M17/00—Producing multi-layer textile fabrics
- D06M17/04—Producing multi-layer textile fabrics by applying synthetic resins as adhesives
- D06M17/10—Polyurethanes polyurea
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
- C08L33/04—Homopolymers or copolymers of esters
- C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
- C08L33/08—Homopolymers or copolymers of acrylic acid esters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4282—Addition polymers
- D04H1/43—Acrylonitrile series
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/4334—Polyamides
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/552—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving by applying solvents or auxiliary agents
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
- D04H1/645—Impregnation followed by a solidification process
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S8/00—Bleaching and dyeing; fluid treatment and chemical modification of textiles and fibers
- Y10S8/12—Wave energy treatment of textiles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2738—Coating or impregnation intended to function as an adhesive to solid surfaces subsequently associated therewith
- Y10T442/2746—Heat-activatable adhesive
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2738—Coating or impregnation intended to function as an adhesive to solid surfaces subsequently associated therewith
- Y10T442/2754—Pressure-sensitive adhesive
Definitions
- the invention described herein relates to a method for bonding a fibrous web material by printing a pattern of a binder onto one or both sides of the web.
- Fibrous webs consist of more or less irregularly bunched fibers of natural and/or synthetic materials which, apart from their mutual intertwining, have no internal cohesion whatsoever.
- the strength resulting from the intertwining of the fibers, particularly in low-weight classes, is so poor that the web has practically no inherent stability. Consequently, the web loses its cohesion as soon as it is without external support.
- the invention relates to a method for bonding such fibrous webs.
- DE-OS No. 26 18 245 discloses a process for bonding a fibrous web material.
- a curable binder is printed in a pattern onto the surface of a fibrous web.
- the binder is cross-linked by exposing the web to electron irradiation.
- the strength of the available prepolymer binders increases with increasing molecular weight.
- the viscosity of the prepolymer binder also increases with the increasing molecular weight of the prepolymer. Viscous, high molecular weight prepolymers are difficult to apply to a fibrous web in a uniform distribution in the relatively small amounts employed. This is particularly true when the fibrous web has received no prebonding, and when the prepolymer is to be applied to only certain areas of the web, such as by a printing operation.
- solvents necessarily involves the high expense of equipment required to keep the air at the work station, and around the production line, free of solvent vapors. There is also the added expense associated with the recovery of excess solvent. Moreover, solvents are flammable and necessarily demand the implementation of elaborate means for the prevention of fires and explosions.
- the thermal prebonding is irreversible upon the final solidification of the web. Such a procedure results, therefore, in the undesirable reduction or destruction of the bulk of the fibrous web material.
- this invention provides a method for bonding a fibrous web which is both simple to operate, and capable of operating speeds greater than 50 m/min.
- This method comprises the steps of compressing, smoothing and heating the fibrous web; applying a UV curable prepolymer binder to the fibrous web; and curing the prepolymer binder by exposing the treated fibrous web to ultraviolet radiation.
- the fibrous web may be compressed, smoothed and heated by passing it through heated rollers, and the prepolymer may be printed onto the fibrous web.
- the prepolymer is cured by exposing the web to ultraviolet light.
- a fibrous web from Rando-Webbers, rollercards, flatcards", or from a spun-bonded fabric machine is passed through the heated rollers of a calender.
- the web is fed through a printing machine which prints a pattern of a prepolymer onto the surface of the fibrous web.
- the prepolymer has a viscosity from about 500 to 5000 centipoise, and preferable a viscosity of from about 1000 to 4000 centipoise.
- the heated roller step serves to smooth and compress the web, without bonding the fibers to each other.
- the individual fibers of the web are heated as they pass through the heated rollers.
- the temperature of the rollers should not exceed about 20° C. below the melting or decomposition point of the material comprising the web fibers.
- the rollers of the calender are desirably at a temperature of from about 120° to about 190° C., and preferably from about 130° to about 180° C.
- the fibrous web is given a smooth external appearance.
- the web can be readily printed upon with a highly viscous prepolymer binder.
- the fibrous web can be readily printed upon even with a highly viscous prepolymer binder, it is not fully understood why this is the case.
- One explanation may be that as a result of passage through the heated rollers, the fibers retain heat, which operates to reduce the viscosity of the prepolymer at the moment of contact with the web, and insures that the fibers are well wetted with the prepolymer binder.
- a mutual bonding of the fibrous web in the area of the intersecting points occurs.
- the fibrous web leaves the printing machine completely undistorted.
- adhesion of individual fibers of the fleece surface to the printing rollers does not occur.
- the practical application of the method of this invention proves to be entirely without problems.
- the printing unit will immediately follow the heated rollers. If possible, their center distance between heated rollers and printer should not exceed 100 cm.
- the structure of the surface of the calender rollers may affect the mechanical properties of the processed web material. Drapability in particular, is affected by the surface structure of the heated rollers.
- the surface of the heated rollers may be of any desired type. Highly polished rollers as well as heavily profiled rollers may be employed. However, particularly good drapability and bulk of the processed fibrous web material are obtained when the surfaces are roughened slightly, or are provided with a very fine surface engraving.
- the two rollers are of completely identical design and are adjusted to the same temperature. However, adjusting the temperature of the rollers so that they differ, may be entirely practical in some cases.
- the design or pattern in which the prepolymer binder is printed onto the fibrous web should enable production of as voluminous a fibrous web as possible, which also has good mechanical strength and good abrasion resistance and, in veiw of its preferred use as a garment interlining is also able to stand up well to dry cleaning.
- a pattern of two groups of parallel lines intersecting at about a 90° angle, and each being inclined at about a 45° angle relative to the direction of travel has proven particularly advantageous.
- the spacing of both groups of lines is preferably identical, and lies in a range of from about 1 to about 5 mm, preferably in a range of from about 1.5 to about 3.5 mm.
- the lines are from about 0.1 to about 0.5 mm wide, and preferably about 0.3 mm wide.
- the pattern may be printed on one or both sides of the fibrous web.
- the nodal points of the pattern on one side of the fibrous web may be located at the empty spaces of the pattern printed onto the opposite side of the web.
- Different patterns may also be printed onto the opposide sides of the web.
- the quantity of prepolymer which is applied will depend on the particular application intended. From about 5 to about 30 percent, and preferably from about 10 to about 25 percent of the prepolymer by weight of the fiber mass, is employed for the preparation of dry-cleanable and washable interlining materials.
- the binder When the fibrous web is uniformly heated during its passage through the heated rollers, the binder can be uniformly distributed over the cross-section of the web.
- a progressive distribution of the prepolymer binder occurs when the surface of the fibrous web opposite to the surface to which the prepolymer binder is applied, is heated to a lower temperature than the surface to which the prepolymer binder is applied. This can be accomplished by adjusting the heated rollers to different temperatures.
- Various UV-curable prepolymer binders may be employed in accordance with this method.
- an appropriately high viscosity is an important property of the prepolymer binder.
- another important criteria for the selection of the prepolymer is its resistance to drycleaning agents such as perchloroethylene. This resistance is produced by a relatively high cross-linking density. Therefore, resins with more than two acrylate functions per molecule are preferred.
- Useful, commercially available resins include acrylated polyesters, polyurethanes, polyepoxides and polyvinyl compounds.
- the polymer may be mixed with a multifunctional acrylate oligomer or with a multifunctional monomer such as pentaerythritol triacrylate, pentaerythritol tetraacrylate, or trimethylolpropane triacrylate to adjust the viscosity of the prepolymer binder.
- a multifunctional acrylate oligomer or with a multifunctional monomer such as pentaerythritol triacrylate, pentaerythritol tetraacrylate, or trimethylolpropane triacrylate to adjust the viscosity of the prepolymer binder.
- Particularly high viscous binders, or binder mixtures may be applied in a heated state in order to reduce their viscosity. It is also possible to use mixtures of two, or more, different prepolymers.
- UV curable binders require the addition of an initiator.
- useful initiators include benzoinbutyl ether, benzoinethyl ether, benzildimethylketal, diethoxy acetophenone, or benzophenone.
- optical brighteners are often advantageous for textile applications. Brighteners which dissolve well in the binders, and are sufficiently UV-resistant to withstand the intensive UV exposure, are preferred. Although optical brighteners are UV absorbers by nature and, therefore, would be expected to have a retarding effect on the hardening reaction, surprisingly, they can be added to the binder without a reduction in the rate of hardening. Moreover, it is possible to add solid or liquid plasticizers such as dibutylphthalate or toluolsulfonamide. The softening effect produced by these compounds relates to the mechanical properties of the cured binder.
- pigments may be added to the binder, but it should be noted that pigments absorb UV radiation to a greater or lesser degree and can, therefore, hinder the curing process.
- any commercially available high pressure mercury lamp which attains a minimum output of 80 Watt/cm is suitable for use during the UV irradiation step. In most cases, both sides of the treated fibrous web are exposed to the ultraviolet light. However, when very light fibrous webs of about 25 g/m 2 or less are employed, it is possible to subject only one side of the fibrous web to UV irradiation.
- the electric power to be installed for the UV irradiation apparatus will depend on the travel speed desired, and on the reactivity of the particular UV-curable prepolymer binder.
- the processing of highly viscous and highly reactive binders has the advantage that the extent of the electric power required is minimal, and the number of UV lamps required can be kept low--even at travel speeds of from about 100 to about 150 m/min. Moreover, it is generally unnecessary to perform the UV treatment under a protective atmosphere, such as a nitrogen atmosphere, in order to increase process speed.
- the bonded fibrous web material produced in accordance with the method of this invention is unusually soft, voluminous and full. Significantly, despite its good strength, the fibrous web product does not have the so-called "springy feel" which heretofore has been characteristic of all fibrous web materials bonded by chemical binders. Thus, the bonded fibrous web of this invention is particularly well suited for use as an interlining material in modern leisure clothing, whose soft and flowing characteristics should not be impaired by a spring-elastic interlining material.
- fibrous web materials which are soft, drapable and full and, at the same time, resistant to chemical cleansers has posed a definite problem to the art.
- the fibrous web materials prepared by the method of this invention are soft and full, and stand up well to washing and dry cleaning. These properties are attributed to the unusual binder distribution within the fibrous web.
- the highly viscous, UV-curable prepolymer binder does not distribute evenly over the entire surface of the fibers, but rather it migrates in minute droplets, preferably to the fiber intersections.
- the bonding points are particularly strong because the binder adheres directly to the fiber surface without the presence of a separate layer of tensides or other substances, as may occur during the application of a conventional binder in an aqueous dispersion. As a result of the relatively small amounts of binder applied not all intersections are bonded.
- the novel fiber bond produced by the method of this invention results in a bonded fibrous web material which is unusually soft and cloth-like.
- the present method can be applied extremely economically and inexpensively. It meets all the prerequisites for large scale application.
- the two rollers are of identical design. Their diameter is 200 mm, and their surface has an 80 mesh engraving which means that the individual depressions have a mutual spacing of about
- the fiber nap Before entering the roller gap, the fiber nap has a thickness of about 10 mm, which is reduced to a thickness of about 1 mm, during the passage through the roller pair.
- the mechanical strength of the fiber fleece is 1.5 N in longitudinal direction and 0.08 N in transverse direction.
- the fibrous web is printed on one side by a printing unit, with a pattern of two groups of parallel lines which intersect at a 90° angle, and which are each inclined at a 45° angle relative to the travel direction.
- the mutual spacing of the lines is 2.5 mm and their width is 0.3 mm.
- the binder mixture employed has a viscosity of 3300 centipoise at 24° C.
- composition of the mixture is as follows:
- the amount applied is 2.5 g/m 2 .
- the web is strengthened by exposure to a high-pressure mercury lamp. Its output is 200 Watt/cm.
- the fibrous web material obtained is 0.23 mm thick. It is soft and drapable. It is printed with a conventional polyamide fusing adhesive in dot form, the quantity applied being 12 g/m 2 . It is subsequently ironed to a ladies blouse material. The laminate is washable and dry-cleanable. No knotting or pilling occurs.
- a crosswise oriented fibrous web weighing 30 g/m 2 and consisting of highly crinkled Nylon-66 fibers of 3.3 Denier with a length of 51 mm is fed at a rate of 50 m/min through a pair of smooth steel rollers heated to 200° C. The gap width between the rollers is 0.01 mm.
- the nap is printed in a rotary film printing machine with the resin mixture described in Example 1. Rollers of the printing machine are electrolytically roughened.
- the printing pattern is analogous to Example 1, except that the grid spacing is 3.5 mm.
- the subsequent cross-linking takes place by the exposure of both sides of the web to a 200 Watt/cm high-pressure mercury lamp.
- the fibrous web material obtained is extremely soft and voluminous. It stands up well to washing and dry cleaning.
- both sides of the nap are printed upon the manner described in Example 1, with a total of 8 g/m 2 of the resin mixture of Example 1.
- the spacing of each printed grid is 2.1 mm.
- the resin is cured by exposing both sides of the printed web to a high-pressure mercury lamp of 200 Watt/cm power output.
- the bonded fibrous web product has a tear strength in the longitudinal direction of 50 N/5 cm strip width.
- the strengthened fibrous web is particularly well suited for use in what is referred to as "overlay" in fiberglass-reinforced plastics.
Abstract
A method for bonding an unbonded fibrous web of natural and/or synthetic fibers by means of a binder which is cured by exposure to UV light, wherein the fibrous web is first compressed, smoothed, and heated, then one or both surfaces of the web is printed with a pattern of a prepolymer binder having a viscosity of from about 500 to 5000 centipoise and the prepolymer binder is cured by exposing the printed fibrous web to ultraviolet light.
Description
The invention described herein relates to a method for bonding a fibrous web material by printing a pattern of a binder onto one or both sides of the web.
Fibrous webs consist of more or less irregularly bunched fibers of natural and/or synthetic materials which, apart from their mutual intertwining, have no internal cohesion whatsoever. The strength resulting from the intertwining of the fibers, particularly in low-weight classes, is so poor that the web has practically no inherent stability. Consequently, the web loses its cohesion as soon as it is without external support. The invention relates to a method for bonding such fibrous webs.
DE-OS No. 26 18 245 discloses a process for bonding a fibrous web material. In accordance with the method of this reference, a curable binder is printed in a pattern onto the surface of a fibrous web. The binder is cross-linked by exposing the web to electron irradiation. There are, however, several difficulties associated with the disclosed method which renders it unsuitable for large-scale production. Such difficulties are the result of the high viscosity of available prepolymers which have to be applied onto fibrous webs having poor mechanical stability.
In their cross-linked state, the strength of the available prepolymer binders increases with increasing molecular weight. To obtain a good consolidation of the fibrous web, it is, therefore, desirable to use prepolymer binders having a high molecular weight. However, the viscosity of the prepolymer binder also increases with the increasing molecular weight of the prepolymer. Viscous, high molecular weight prepolymers are difficult to apply to a fibrous web in a uniform distribution in the relatively small amounts employed. This is particularly true when the fibrous web has received no prebonding, and when the prepolymer is to be applied to only certain areas of the web, such as by a printing operation.
In the reference cited above, this difficulty is avoided by employing a prepolymer binder whose viscosity has been reduced by the addition of a solvent. Moreover, in Example 9 of the reference, prior to the addition of the prepolymer binders, the fibrous web is prebonded by the thermal activation of low-melting bonding fibers. Both procedures have disadvantageous aspects.
The use of solvents necessarily involves the high expense of equipment required to keep the air at the work station, and around the production line, free of solvent vapors. There is also the added expense associated with the recovery of excess solvent. Moreover, solvents are flammable and necessarily demand the implementation of elaborate means for the prevention of fires and explosions.
With regard to the thermal prebonding procedure disclosed by the cited reference, the thermal prebonding is irreversible upon the final solidification of the web. Such a procedure results, therefore, in the undesirable reduction or destruction of the bulk of the fibrous web material.
In addition to the technical difficulties discussed above, a large-scale application of the method disclosed by the cited reference is unfeasible since the prepolymer binder after being printed onto the fibrous web, must be cross-linked under a nitrogen atmosphere. Feeds of only 6 m/min are disclosed which are far below the operating speeds currently employed.
As an alternative to solvents it is known to add monomeric low viscosity esters of acrylic acid to the prepolymer binder in order to reduce its viscosity. The viscosity lowering esters are incorporated into the polymer network during the irradiation step. Acrylic acid esters useful for this purpose include butyl acrylate, hydroxyethyl acrylate, hydroxypropyl acrylate, butanediol diacrylate, hexanediol diacrylate, trimethylolpropane triacrylate, and others. Generally, the viscosity-lowering effect of these thinners is the greater, the lower their molecular weight. However, volatility and toxicity also increase as the molecular weight of the ester decreases. Polymers from monomeric acrylic acid esters are usually brittle, fragile products of inadequate mechanical strength. When the acrylic acid ester monomers are polymerized with prepolymer binders, they impair the mechanical properties of the prepolymer binders as well as the flexibility, toughness and softness of the fibrous web material.
Another problem associated with the use of acrylic acid esters results from the fact that residual monomer not reacted during the polymerization of the prepolymer/monomer mixture remains in the polymerization product and can cause skin irritations as well as disagreeable odors.
Due to the kinetics of the polymerization reaction of the monofunctional monomers, unconverted monomer will always be found in the polymerization product. In commercial monomer/prepolymer mixtures, 1% by weight or more of these monomers remains in the polymerization product. With regard to difunctional monomers, the danger of unreacted residual monomer is considerably reduced, but it is still present. Only acrylate monomers which are trifunctional, tetrafunctional, or higher, are incorporated completely into the polymer network. Thus, if possible, the use of monofunctional and difunctional reactive thinners should be avoided. However, mixtures of prepolymers with oligomers or monomers which are trifunctional or higher are always highly viscous, and it has thus far been impossible to process them.
It is an object of this invention to provide a method for bonding a fibrous web material by printing a viscous prepolymer binder onto the fibrous web which does not require prebonding of the web prior to the printing step.
In accordance with the foregoing objective this invention provides a method for bonding a fibrous web which is both simple to operate, and capable of operating speeds greater than 50 m/min. This method comprises the steps of compressing, smoothing and heating the fibrous web; applying a UV curable prepolymer binder to the fibrous web; and curing the prepolymer binder by exposing the treated fibrous web to ultraviolet radiation.
The fibrous web may be compressed, smoothed and heated by passing it through heated rollers, and the prepolymer may be printed onto the fibrous web. The prepolymer is cured by exposing the web to ultraviolet light.
In accordance with the method of this invention, a fibrous web from Rando-Webbers, rollercards, flatcards", or from a spun-bonded fabric machine is passed through the heated rollers of a calender. Immediately following this step, the web is fed through a printing machine which prints a pattern of a prepolymer onto the surface of the fibrous web. The prepolymer has a viscosity from about 500 to 5000 centipoise, and preferable a viscosity of from about 1000 to 4000 centipoise.
The heated roller step serves to smooth and compress the web, without bonding the fibers to each other. In addition, the individual fibers of the web are heated as they pass through the heated rollers. The temperature of the rollers should not exceed about 20° C. below the melting or decomposition point of the material comprising the web fibers. When the fibrous web is fed through the heated rollers at a speed of from about 30 to about 150 m/min, the rollers of the calender are desirably at a temperature of from about 120° to about 190° C., and preferably from about 130° to about 180° C.
Although the heated roller conditions employed do not cause the web fibers to bond to each other, the fibrous web is given a smooth external appearance. Thus, the web can be readily printed upon with a highly viscous prepolymer binder. Surprisingly, there are no differences whatsoever between the printability of fibrous webs formed from synthetic fibers and webs formed from natural fibers.
Not even a temporary bond, as could occur as a result of the removal of moisture from the various web fibers, is produced during the calendering step of this invention. The inherent stability of the fibrous web is relatively low when it leaves the calender, and it cannot be handled in a normal manner, such as by winding or unwinding.
Although it is clear that the fibrous web can be readily printed upon even with a highly viscous prepolymer binder, it is not fully understood why this is the case. One explanation may be that as a result of passage through the heated rollers, the fibers retain heat, which operates to reduce the viscosity of the prepolymer at the moment of contact with the web, and insures that the fibers are well wetted with the prepolymer binder. At the same time, a mutual bonding of the fibrous web in the area of the intersecting points occurs. The fibrous web leaves the printing machine completely undistorted. Surprisingly, adhesion of individual fibers of the fleece surface to the printing rollers does not occur. Thus, the practical application of the method of this invention proves to be entirely without problems. Moreover, it is subject to no restrictions whatever regarding the variation of the printing pattern used.
Preferably, the printing unit will immediately follow the heated rollers. If possible, their center distance between heated rollers and printer should not exceed 100 cm. In addition, it has been found that the structure of the surface of the calender rollers may affect the mechanical properties of the processed web material. Drapability in particular, is affected by the surface structure of the heated rollers.
Basically, the surface of the heated rollers may be of any desired type. Highly polished rollers as well as heavily profiled rollers may be employed. However, particularly good drapability and bulk of the processed fibrous web material are obtained when the surfaces are roughened slightly, or are provided with a very fine surface engraving. Usually, the two rollers are of completely identical design and are adjusted to the same temperature. However, adjusting the temperature of the rollers so that they differ, may be entirely practical in some cases.
The design or pattern in which the prepolymer binder is printed onto the fibrous web should enable production of as voluminous a fibrous web as possible, which also has good mechanical strength and good abrasion resistance and, in veiw of its preferred use as a garment interlining is also able to stand up well to dry cleaning. A pattern of two groups of parallel lines intersecting at about a 90° angle, and each being inclined at about a 45° angle relative to the direction of travel has proven particularly advantageous. The spacing of both groups of lines is preferably identical, and lies in a range of from about 1 to about 5 mm, preferably in a range of from about 1.5 to about 3.5 mm. The lines are from about 0.1 to about 0.5 mm wide, and preferably about 0.3 mm wide.
The pattern may be printed on one or both sides of the fibrous web. In the latter case, the nodal points of the pattern on one side of the fibrous web may be located at the empty spaces of the pattern printed onto the opposite side of the web. Different patterns may also be printed onto the opposide sides of the web.
The quantity of prepolymer which is applied will depend on the particular application intended. From about 5 to about 30 percent, and preferably from about 10 to about 25 percent of the prepolymer by weight of the fiber mass, is employed for the preparation of dry-cleanable and washable interlining materials.
When the fibrous web is uniformly heated during its passage through the heated rollers, the binder can be uniformly distributed over the cross-section of the web. A progressive distribution of the prepolymer binder occurs when the surface of the fibrous web opposite to the surface to which the prepolymer binder is applied, is heated to a lower temperature than the surface to which the prepolymer binder is applied. This can be accomplished by adjusting the heated rollers to different temperatures.
It is an advantage of the present invention that, as opposed to processes which print with solutions or aqueous dispersions of the prepolymer binder, no binder migration takes place during curing. Rather, upon irradiation with ultraviolet light, the binder is solidified directly in its original position. Therefore, the procedure can be controlled easily in such a way so that no web delamination occurs.
Various UV-curable prepolymer binders may be employed in accordance with this method. However, an appropriately high viscosity is an important property of the prepolymer binder. For the preferred end use of the fibrous web product as interlining material for use in garment manufacture, another important criteria for the selection of the prepolymer is its resistance to drycleaning agents such as perchloroethylene. This resistance is produced by a relatively high cross-linking density. Therefore, resins with more than two acrylate functions per molecule are preferred. Useful, commercially available resins include acrylated polyesters, polyurethanes, polyepoxides and polyvinyl compounds. The polymer may be mixed with a multifunctional acrylate oligomer or with a multifunctional monomer such as pentaerythritol triacrylate, pentaerythritol tetraacrylate, or trimethylolpropane triacrylate to adjust the viscosity of the prepolymer binder. Particularly high viscous binders, or binder mixtures, may be applied in a heated state in order to reduce their viscosity. It is also possible to use mixtures of two, or more, different prepolymers.
For activation, UV curable binders require the addition of an initiator. Useful initiators include benzoinbutyl ether, benzoinethyl ether, benzildimethylketal, diethoxy acetophenone, or benzophenone.
It is a particular advantage of the present method that relatively little of the expensive initiator is required. The rate of curing during the UV irradiaton step increases with the initial viscosity of the prepolymer employed. Therefore, since the processing of highly viscous resins or resin mixtures is made possible by the present method, relatively little initiator is required.
In addition to the initiator, substances which intensify the initiator's effect or further reduce the amount of initiator required may be employed. Such substances include amines such as triethanol amine. In addition, if required, optical brigtheners may also be added to the prepolymer mixture. The addition of optical brighteners is often advantageous for textile applications. Brighteners which dissolve well in the binders, and are sufficiently UV-resistant to withstand the intensive UV exposure, are preferred. Although optical brighteners are UV absorbers by nature and, therefore, would be expected to have a retarding effect on the hardening reaction, surprisingly, they can be added to the binder without a reduction in the rate of hardening. Moreover, it is possible to add solid or liquid plasticizers such as dibutylphthalate or toluolsulfonamide. The softening effect produced by these compounds relates to the mechanical properties of the cured binder.
If desired, pigments may be added to the binder, but it should be noted that pigments absorb UV radiation to a greater or lesser degree and can, therefore, hinder the curing process.
Finally, it is also possible to add abrasives such as quartz powder, corundum, etc. to the resin mixture. Through such additions, particularly flexible, materials for grinding, or abrasion purposes are obtained.
Any commercially available high pressure mercury lamp which attains a minimum output of 80 Watt/cm is suitable for use during the UV irradiation step. In most cases, both sides of the treated fibrous web are exposed to the ultraviolet light. However, when very light fibrous webs of about 25 g/m2 or less are employed, it is possible to subject only one side of the fibrous web to UV irradiation.
The electric power to be installed for the UV irradiation apparatus will depend on the travel speed desired, and on the reactivity of the particular UV-curable prepolymer binder. The processing of highly viscous and highly reactive binders has the advantage that the extent of the electric power required is minimal, and the number of UV lamps required can be kept low--even at travel speeds of from about 100 to about 150 m/min. Moreover, it is generally unnecessary to perform the UV treatment under a protective atmosphere, such as a nitrogen atmosphere, in order to increase process speed.
The bonded fibrous web material produced in accordance with the method of this invention is unusually soft, voluminous and full. Significantly, despite its good strength, the fibrous web product does not have the so-called "springy feel" which heretofore has been characteristic of all fibrous web materials bonded by chemical binders. Thus, the bonded fibrous web of this invention is particularly well suited for use as an interlining material in modern leisure clothing, whose soft and flowing characteristics should not be impaired by a spring-elastic interlining material.
The production of fibrous web materials which are soft, drapable and full and, at the same time, resistant to chemical cleansers has posed a definite problem to the art. The fibrous web materials prepared by the method of this invention, however, are soft and full, and stand up well to washing and dry cleaning. These properties are attributed to the unusual binder distribution within the fibrous web. At the moment of printing, the highly viscous, UV-curable prepolymer binder does not distribute evenly over the entire surface of the fibers, but rather it migrates in minute droplets, preferably to the fiber intersections. The bonding points are particularly strong because the binder adheres directly to the fiber surface without the presence of a separate layer of tensides or other substances, as may occur during the application of a conventional binder in an aqueous dispersion. As a result of the relatively small amounts of binder applied not all intersections are bonded. The novel fiber bond produced by the method of this invention results in a bonded fibrous web material which is unusually soft and cloth-like. The present method can be applied extremely economically and inexpensively. It meets all the prerequisites for large scale application.
The invention will be described further with reference to the following examples.
A lengthwise oriented fiber fleece weighing 20 g/m2, and consisting of polyester fibers of 1.3 dtex Denier with a length of 36 mm, is fed through a pair of metal rollers at a speed of 100 m/min. The two rollers are of identical design. Their diameter is 200 mm, and their surface has an 80 mesh engraving which means that the individual depressions have a mutual spacing of about
0.3 mm, and a depth of about 0.1 mm. The rollers are heated to 175° C. The spacing between the rollers is adjusted so that the two rollers barely touch, but do not exert any appreciable pressure on each other. Before entering the roller gap, the fiber nap has a thickness of about 10 mm, which is reduced to a thickness of about 1 mm, during the passage through the roller pair.
After compression and tempering, the mechanical strength of the fiber fleece is 1.5 N in longitudinal direction and 0.08 N in transverse direction.
At a center distance of 800 mm from the heated rollers the fibrous web is printed on one side by a printing unit, with a pattern of two groups of parallel lines which intersect at a 90° angle, and which are each inclined at a 45° angle relative to the travel direction. The mutual spacing of the lines is 2.5 mm and their width is 0.3 mm.
The binder mixture employed has a viscosity of 3300 centipoise at 24° C.
The composition of the mixture is as follows:
______________________________________ Parts by Weight ______________________________________ Polyurethane prepolymer (Ebecryl 830, Union Chimique Belge) 50.00 Polyurethane oligomer (OTA 480, Union Chimique Belge) 50.00 Optical brightener (Hostalux KCB, Hoechst AG) 0.03 Benzildimethylketal (Luzirin BDK, BASF AG) 1.00 Benzophenone 2.00 Methyldiethanol amine 3.00 ______________________________________
The amount applied is 2.5 g/m2. Immediately after printing is complete, the web is strengthened by exposure to a high-pressure mercury lamp. Its output is 200 Watt/cm.
The fibrous web material obtained is 0.23 mm thick. It is soft and drapable. It is printed with a conventional polyamide fusing adhesive in dot form, the quantity applied being 12 g/m2. It is subsequently ironed to a ladies blouse material. The laminate is washable and dry-cleanable. No knotting or pilling occurs.
A crosswise oriented fibrous web weighing 30 g/m2 and consisting of highly crinkled Nylon-66 fibers of 3.3 Denier with a length of 51 mm is fed at a rate of 50 m/min through a pair of smooth steel rollers heated to 200° C. The gap width between the rollers is 0.01 mm. Immediately thereafter the nap is printed in a rotary film printing machine with the resin mixture described in Example 1. Rollers of the printing machine are electrolytically roughened. The printing pattern is analogous to Example 1, except that the grid spacing is 3.5 mm.
The subsequent cross-linking takes place by the exposure of both sides of the web to a 200 Watt/cm high-pressure mercury lamp.
The fibrous web material obtained is extremely soft and voluminous. It stands up well to washing and dry cleaning.
A lengthwise oriented fiber nap weighing 35 g/m2 and consisting of shiny polyacrylonitrile fibers of 3.3 Denier, with a length of 60 mm, is fed at a rate of 80 m/min through two rollers heated to 195° C.
Immediately after calendering, both sides of the nap are printed upon the manner described in Example 1, with a total of 8 g/m2 of the resin mixture of Example 1. The spacing of each printed grid is 2.1 mm. The resin is cured by exposing both sides of the printed web to a high-pressure mercury lamp of 200 Watt/cm power output.
The bonded fibrous web product has a tear strength in the longitudinal direction of 50 N/5 cm strip width. The strengthened fibrous web is particularly well suited for use in what is referred to as "overlay" in fiberglass-reinforced plastics.
The invention has been described in terms of specific embodiments set forth in detail herein. It should be understood, however, that these are by way of illustration only and that the invention is not necessarily limited thereto. Modifications and variations will be apparent from this disclosure and may be resorted to without departing from the spirit of this invention, as those skilled in the art will readily understand. Accordingly, such variations and modifications of the disclosed embodiments are considered to be within the scope of this invention and the following claims.
Claims (19)
1. A method for bonding a fibrous web comprising the steps of:
(a) compressing and smoothing a fibrous web by passing said web through heated rollers, said rollers being at a temperature at least about 20° C. below the melting point of the fibers comprising said web, and wherein said fibrous web is heated by said rollers but the fibers comprising said web are not bonded together; and
(b) applying a UV hardenable solvent-free prepolymer binder composition to said fibrous web, said prepolymer having a viscosity of from about 500 to about 5000 centipoise during application; and
(c) curing said prepolymer binder by exposing said treated fibrous web to ultraviolet radiation.
2. The method according to claim 1 wherein said prepolymer is printed onto said fibrous web.
3. The method according to claim 2 wherein the weight of said prepolymer binder printed onto the fibrous web is from about 5 to about 30% of the weight of said fibrous web.
4. The method according to claim 3 wherein
(a) the spacing between said rollers is adapted such that said rollers contact each other with minimal pressure.
5. The method according to claim 4 wherein
(a) the temperature of said rollers is from about 120° C. to about 190° C., and
(b) said fibrous web is fed through said rollers at a rate of from about 50 to about 150 m/min.
6. The method according to claim 3 wherein said prepolymer binder composition comprises a solution of said prepolymer and a thinner for said prepolymer.
7. The method according to claim 6 wherein said thinner is selected from the group consisting of tri- or tetrafunctional acrylate monomers or multifunctional acrylate oligomers.
8. The method according to claim 7 wherein said thinner is a multifunctional acrylate monomer selected from the group consisting of pentaerythrite triacrylate, pentaerythrite tetraacrylate, or trimethylolpropane triacrylate; and said prepolymer is selected from the group consisting of the low molecular weight polyurethane, polyester or polyepoxy prepolymers.
9. The method according to claim 3 wherein said prepolymer composition is heated.
10. The method according to claim 2 wherein said prepolymer binder is cured by exposing said fibrous web to a high-pressure mercury lamp having a radiation output of at least about 80 Watts per cm of fibrous web width.
11. The method according to claim 2 wherein the surface of said rollers is roughened.
12. The method according to claim 2 wherein said fibrous web is comprised of nylon fibers or polyacrylonitrile fibers.
13. The method according to claim 3 wherein the weight of said prepolymer is from about 10 to about 25 percent of the weight of said fibrous web, and said prepolymer binder composition has a viscosity of from about 1000 to about 4000 centipoise.
14. The method according to claim 3 wherein the viscosity of said prepolymer binder composition is adjusted by the addition of an oligomer to said prepolymer.
15. The method according to claim 3 wherein said prepolymer binder composition comprises a mixture of polyurethane prepolymer with polyurethane oligomer.
16. In a method for bonding a fibrous web by printing a prepolymer binder onto one or both surfaces of the fibrous web, and subsequently cross-linking said prepolymer binder, the improvement which comprises:
(a) compressing, smoothing and heating said fibrous web immediately prior to printing a solvent-free prepolymer binder onto said web, wherein said fibrous web is passed through rollers heated to a temperature at least about 20° C. below the melting point of the fibers comprising said web, such that said web is compressed, smoothed and heated but the fibers of said web are not bonded together and wherein said prepolymer binder has a viscosity of from about 500 to 5000 centipoise, and is printed onto said fibrous web in an amount comprising from about 5 to about 30% of the weight of said fibrous web; and
(b) subsequent to printing said prepolymer binder onto said fibrous web, immediately exposing said fibrous web to ultraviolet light to cure said prepolymer binder.
17. The method according to claim 16 wherein
(a) said fibrous web is smoothed, compressed and heated by passing it through heated rollers; and
(b) the spacing between said rollers is adapted such that said rollers contact each other with minimal pressure; and
(c) the temperature of said rollers is adjusted to within the range of from about 120° to about 190° C., and at least about 20° C. below the melting point of the fibers of said web; and
(d) said fibrous web is fed through said rollers at the rate of from about 50 to about 150 m/min.
18. The method according to claims 16 or 17 wherein
(a) the viscosity of said prepolymer is adjusted by heating said prepolymer and/or by the addition to said prepolymer of an acrylate oligomer or a multifunctional acrylate monomer; said acrylate monomer being selected from the group consisting of pentaerythritol triacrylate, pentaerythritol tetraacrylate and trimethylolpropane triacrylate, and
(b) said prepolymer is selected from the group consisting of the low molecular weight polyurethane, polyester and polyepoxy prepolymers.
19. The method according to claim 18 wherein said fibrous web having said prepolymer printed thereon is exposed to a high-pressure mercury lamp having an output of at least about 80 Watts per cm of width of said fibrous web.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP78101813.0 | 1978-12-21 | ||
EP78101813A EP0012776B1 (en) | 1978-12-21 | 1978-12-21 | Process for bonding non-woven fabrics |
Publications (1)
Publication Number | Publication Date |
---|---|
US4300968A true US4300968A (en) | 1981-11-17 |
Family
ID=8185950
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US06/104,770 Expired - Lifetime US4300968A (en) | 1978-12-21 | 1979-12-18 | Method for bonding fibrous web materials |
Country Status (11)
Country | Link |
---|---|
US (1) | US4300968A (en) |
EP (1) | EP0012776B1 (en) |
JP (1) | JPS6059347B2 (en) |
AR (1) | AR221913A1 (en) |
AT (1) | AT383625B (en) |
AU (1) | AU528442B2 (en) |
CA (1) | CA1123782A (en) |
DE (1) | DE2862131D1 (en) |
ES (1) | ES486374A1 (en) |
HK (1) | HK40284A (en) |
ZA (1) | ZA796970B (en) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4545831A (en) * | 1982-09-13 | 1985-10-08 | The Mount Sinai School Of Medicine | Method for transferring a thin tissue section |
US4568558A (en) * | 1984-02-11 | 1986-02-04 | Kulzer & Co. Gmbh | Method for producing orthodontic devices and appliances |
US5444105A (en) * | 1982-09-13 | 1995-08-22 | Mount Sinai School Of Medicine Of The City University Of New York | Specimen mounting adhesive composition |
WO1996039259A1 (en) | 1995-06-06 | 1996-12-12 | Kasmark James W Jr | Machine and method of making a filter |
US6500289B2 (en) | 1998-11-12 | 2002-12-31 | Kimberly-Clark Worldwide, Inc. | Method of using water-borne epoxies and urethanes in print bonding fluid and products made therefrom |
US6689242B2 (en) | 2001-03-26 | 2004-02-10 | First Quality Nonwovens, Inc. | Acquisition/distribution layer and method of making same |
US20050233137A1 (en) * | 2004-04-15 | 2005-10-20 | Anthony Angelino | Undergarments having finished edges and methods therefor |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4291087A (en) * | 1979-06-12 | 1981-09-22 | Rohm And Haas Company | Non-woven fabrics bonded by radiation-curable, hazard-free binders |
DE3049037C2 (en) * | 1980-12-24 | 1984-05-03 | Fa. Carl Freudenberg, 6940 Weinheim | Process for the simultaneous, continuous consolidation and coating of a nonwoven fabric |
DE3049036C2 (en) * | 1980-12-24 | 1984-09-13 | Fa. Carl Freudenberg, 6940 Weinheim | Process for the simultaneous, continuous consolidation and coating of a nonwoven fabric |
DE3916127A1 (en) * | 1989-05-18 | 1990-11-22 | Kuesters Eduard Maschf | Process to chemically treat textile fabrics - uses irradiation in formula |
US5169571A (en) * | 1991-04-16 | 1992-12-08 | The C.A. Lawton Company | Mat forming process and apparatus |
DE102009013028A1 (en) * | 2009-03-16 | 2010-10-14 | Carl Freudenberg Kg | Non-woven fabric with a carrier layer of melt-spun thermoplastic polyester, bonded with a binder applied as an aqueous dispersion in a pattern of discrete dots over the fabric surface |
DE202009007662U1 (en) * | 2009-05-27 | 2009-08-27 | Perick Management Gmbh | Textile carrier material |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2618245A1 (en) | 1976-04-26 | 1977-11-03 | Johnson & Johnson | RESIN-GLUED TEXTILE COMPOSITE FABRIC AND THEIR MANUFACTURING PROCESS |
US4146417A (en) * | 1976-05-04 | 1979-03-27 | Johnson & Johnson | Method for producing bonded nonwoven fabrics using ionizing radiation |
US4212901A (en) * | 1977-07-08 | 1980-07-15 | Akzo N.V. | Method for treating a substrate with a radiation and chemically curable coating composition |
US4222835A (en) * | 1978-05-25 | 1980-09-16 | Westinghouse Electric Corp. | In depth curing of resins induced by UV radiation |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1815329A1 (en) * | 1968-12-18 | 1970-08-06 | Basf Ag | Polyester impregnated fibre mats |
GB1346063A (en) * | 1970-05-19 | 1974-02-06 | Ici Ltd | Bonded non-woven webs |
GB1349058A (en) * | 1970-05-19 | 1974-03-27 | Ici Ltd | Non-woven webs |
-
1978
- 1978-12-21 DE DE7878101813T patent/DE2862131D1/en not_active Expired
- 1978-12-21 EP EP78101813A patent/EP0012776B1/en not_active Expired
-
1979
- 1979-11-07 AU AU52575/79A patent/AU528442B2/en not_active Ceased
- 1979-11-27 ES ES486374A patent/ES486374A1/en not_active Expired
- 1979-11-29 AR AR279075A patent/AR221913A1/en active
- 1979-12-13 CA CA341,872A patent/CA1123782A/en not_active Expired
- 1979-12-18 JP JP54164641A patent/JPS6059347B2/en not_active Expired
- 1979-12-18 US US06/104,770 patent/US4300968A/en not_active Expired - Lifetime
- 1979-12-20 AT AT0804879A patent/AT383625B/en not_active IP Right Cessation
- 1979-12-21 ZA ZA00796970A patent/ZA796970B/en unknown
-
1984
- 1984-05-10 HK HK402/84A patent/HK40284A/en unknown
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2618245A1 (en) | 1976-04-26 | 1977-11-03 | Johnson & Johnson | RESIN-GLUED TEXTILE COMPOSITE FABRIC AND THEIR MANUFACTURING PROCESS |
US4146417A (en) * | 1976-05-04 | 1979-03-27 | Johnson & Johnson | Method for producing bonded nonwoven fabrics using ionizing radiation |
US4212901A (en) * | 1977-07-08 | 1980-07-15 | Akzo N.V. | Method for treating a substrate with a radiation and chemically curable coating composition |
US4222835A (en) * | 1978-05-25 | 1980-09-16 | Westinghouse Electric Corp. | In depth curing of resins induced by UV radiation |
Cited By (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4545831A (en) * | 1982-09-13 | 1985-10-08 | The Mount Sinai School Of Medicine | Method for transferring a thin tissue section |
US5444105A (en) * | 1982-09-13 | 1995-08-22 | Mount Sinai School Of Medicine Of The City University Of New York | Specimen mounting adhesive composition |
US4568558A (en) * | 1984-02-11 | 1986-02-04 | Kulzer & Co. Gmbh | Method for producing orthodontic devices and appliances |
US4656053A (en) * | 1984-02-11 | 1987-04-07 | Kulzer & Co. Gmbh | Method for producing orthodontic devices and appliances |
WO1996039259A1 (en) | 1995-06-06 | 1996-12-12 | Kasmark James W Jr | Machine and method of making a filter |
US6500289B2 (en) | 1998-11-12 | 2002-12-31 | Kimberly-Clark Worldwide, Inc. | Method of using water-borne epoxies and urethanes in print bonding fluid and products made therefrom |
US6689242B2 (en) | 2001-03-26 | 2004-02-10 | First Quality Nonwovens, Inc. | Acquisition/distribution layer and method of making same |
US20050233137A1 (en) * | 2004-04-15 | 2005-10-20 | Anthony Angelino | Undergarments having finished edges and methods therefor |
US7228809B2 (en) * | 2004-04-15 | 2007-06-12 | Cupid Foundations, Inc. | Undergarments having finished edges and methods therefor |
US20070204782A1 (en) * | 2004-04-15 | 2007-09-06 | Cupid Foundations, Inc. | Undergarments having finished edges and methods therefor |
US20080295227A1 (en) * | 2004-04-15 | 2008-12-04 | Cupid Foundations, Inc. | Undergarments having finished edges and methods therefor |
US8176864B2 (en) | 2004-04-15 | 2012-05-15 | Cupid Foundations, Inc. | Undergarments having finished edges and methods therefor |
US8215251B2 (en) | 2004-04-15 | 2012-07-10 | Cupid Foundations, Inc. | Undergarments having finished edges and methods therefor |
US8839728B2 (en) | 2004-04-15 | 2014-09-23 | Cupid Foundations, Inc. | Undergarments having finished edges and methods therefor |
Also Published As
Publication number | Publication date |
---|---|
AU528442B2 (en) | 1983-04-28 |
ATA804879A (en) | 1986-12-15 |
JPS5593879A (en) | 1980-07-16 |
JPS6059347B2 (en) | 1985-12-24 |
EP0012776A1 (en) | 1980-07-09 |
AU5257579A (en) | 1980-06-26 |
AR221913A1 (en) | 1981-03-31 |
ZA796970B (en) | 1980-11-26 |
HK40284A (en) | 1984-05-18 |
AT383625B (en) | 1987-07-27 |
EP0012776B1 (en) | 1982-12-15 |
DE2862131D1 (en) | 1983-01-20 |
ES486374A1 (en) | 1980-09-16 |
CA1123782A (en) | 1982-05-18 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US4300968A (en) | Method for bonding fibrous web materials | |
US4747346A (en) | Method of stencil printing a substrate with foam | |
US4943472A (en) | Improved preimpregnated material comprising a particulate thermosetting resin suitable for use in the formation of a substantially void-free fiber-reinforced composite article | |
US4919739A (en) | Production of improved preimpregnated material comprising a particulate thermosetting resin suitable for use in the formation of a substantially void-free fiber-reinforced composite article | |
US4041197A (en) | Method for coating a substrate with plastic | |
US3684637A (en) | Simulated leather laminate and its preparation | |
US4146417A (en) | Method for producing bonded nonwoven fabrics using ionizing radiation | |
JPH01103617A (en) | Polymer network | |
CA2054383A1 (en) | Method for coating of a roll, and a roll coating | |
JPH0610258A (en) | Method for bonding nonwoven fabric | |
US3709805A (en) | Production of polymers with a fibrous structure | |
US3265527A (en) | Process of preparing non-woven polymer bonded fabric and article | |
CA1182068A (en) | Process for simultaneous and continuous consolidation and coating of a non-woven textile | |
DE2221087A1 (en) | Products with a plush surface and process for their manufacture | |
US5439737A (en) | Two-phase fusible interlining made of a semi-interpenetrating network of thermoplastic resins | |
US3753842A (en) | Non-woven textile fabric | |
EP0344529B1 (en) | Web with finishing coating useful as coated abrasive backing | |
US3620797A (en) | Impregnation of a nonwoven fabric | |
DE2301481A1 (en) | CARPET PAD | |
JPH11268060A (en) | Manufacture of polyethylene material | |
KR880000927B1 (en) | Impregnated non-woven sheet material and products produced therewith | |
US3542617A (en) | Method for producing a leather-like material | |
US3558263A (en) | Potassium iodide cross-linking inhibitor for n-methylolacrylamide | |
CA1076518A (en) | Strong durable nonwoven fabric and method of manufacturing the same | |
US5421945A (en) | Process and device for mass conservation of archives |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STCF | Information on status: patent grant |
Free format text: PATENTED CASE |